Lexmark T430 Service Manual
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Lexmark T430 Service Manual

Lexmark T430 Service Manual

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See also: User Manual , Setup Manual
Revised: February 2005
Lexmark™ T430
4048-1xx
• Table of contents
• Start diagnostics
• Safety and notices
• Trademarks
• Index
Lexmark and Lexmark with diamond
design are trademarks of Lexmark
International, Inc., registered in the
United States and/or other countries.

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Summary of Contents for Lexmark T430

  • Page 1 Revised: February 2005 Lexmark™ T430 4048-1xx • Table of contents • Start diagnostics • Safety and notices • Trademarks • Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
  • Page 2 Lexmark, Lexmark with diamond design, MarkNet, and MarkVision are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. ImageQuick, Optra Forms, and PrictureGrade are trademarks of Lemark International, Inc.

  • Page 3: Table Of Contents

    4048-1xx Table of Contents Laser notices ..........vii Safety information .
  • Page 4 4048-1xx Service checks ..........2-36 Cooling fan service check .
  • Page 5 4048-1xx Repair information ......... . . 4-1 Handling ESD-sensitive parts .
  • Page 6 4048-1xx Cartridge coupling assembly removal ......4-65 Upper MPF housing assembly (with paper flag) removal ..4-66 MPF paper sensor removal .

  • Page 7: Laser Notices

    4048-1xx Laser notices The following laser notice labels may be affixed to this printer as shown: Laser advisory label Laser notices...

  • Page 8: Laser Notice

    4048-1xx Laser notice The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825-1.
  • Page 9 4048-1xx Avis relatif à l’utilisation de laser Pour les Etats-Unis : cette imprimante est certifiée conforme aux provisions DHHS 21 CFR alinéa J concernant les produits laser de Classe I (1). Pour les autres pays : cette imprimante répond aux normes IEC 60825-1 relatives aux produits laser de Classe I.
  • Page 10 4048-1xx Avisos sobre el láser Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1) establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en los demás países, reúne todas las condiciones expuestas en la norma IEC 60825-1 para productos láser de Clase I (1).
  • Page 11 4048-1xx Laserinformatie De printer voldoet aan de eisen die gesteld worden aan een laserprodukt van klasse I. Voor de Verenigde Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in IEC 60825-1. Laserprodukten van klasse I worden niet als ongevaarlijk aangemerkt.
  • Page 12 4048-1xx Huomautus laserlaitteesta Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS 21 CFR Subchapter J -määrityksen mukainen ja muualla luokan I laserlaitteiden IEC 60825-1 -määrityksen mukainen. Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle. Kirjoittimessa on sisäinen luokan IIIb (3b) 5 milliwatin galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometriä.
  • Page 13 4048-1xx Laser-melding Skriveren er godkjent i USA etter kravene i DHHS 21 CFR, underkapittel J, for klasse I (1) laserprodukter, og er i andre land godkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC 60825-1. Klasse I-laserprodukter er ikke å betrakte som farlige. Skriveren inneholder internt en klasse IIIb (3b)-laser, som består av en gallium-arsenlaserenhet som avgir stråling i bølgelengdeområdet 770-795 nanometer.
  • Page 14 4048-1xx Japanese Laser Notice Chinese Laser Notice Service Manual...
  • Page 15 4048-1xx Korean Laser Notice Laser notices...
  • Page 16 4048-1xx Service Manual...

  • Page 17: Safety Information

    4048-1xx Safety information • The safety of this product is based on testing and approvals of the original design and specific components. The manufacturer is not responsible for safety in the event of use of unauthorized replacement parts. • The maintenance information for this product has been prepared for use by a professional service person and is not intended to be used by others.
  • Page 18 4048-10x Norme di sicurezza • La sicurezza del prodotto si basa sui test e sull'approvazione del progetto originale e dei componenti specifici. Il produttore non è responsabile per la sicurezza in caso di sostituzione non autorizzata delle parti. • Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di assistenza autorizzato.
  • Page 19 4048-1xx Pautas de Seguridad • La seguridad de este producto se basa en pruebas y aprobaciones del diseño original y componentes específicos. El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no autorizadas. •...
  • Page 20 4048-10x Informació de Seguretat • La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els components específics. El fabricant no es fa responsable de les qüestions de seguretat si s'utilitzen peces de recanvi no autoritzades. •...
  • Page 21 4048-1xx Safety information...

  • Page 22: Preface

    4048-10x Preface This manual contains maintenance procedures for service personnel. It is divided into the following chapters: 1. General information contains a general description of the printer and the maintenance approach used to repair it. Special tools and test equipment are listed, as well as general environmental and safety instructions.

  • Page 23: General Information

    4048-1xx 1. General information The Lexmark™ T430 (4048-1xx) laser printer is a monochrome laser printer designed for individual users or small workgroups. Models There are three models, differing on standard features, including standard memory. For information on standard and optional memory, see “Memory and user flash memory”...

  • Page 24: Special Tools

    4048-1xx Special tools Long Phillips screwdriver (approximately 6–inch shank) Slotted screwdriver Small Phillips screwdriver Spring hook When taking voltage readings, always use the printer frame as ground unless another ground is specified. Printer identification Serial number Look for the serial number label on the inside front cover of the printer.

  • Page 25: Printer Features And Specifications

    4048-1xx Printer features and specifications Operator panel The operator panel consists of a two-line display and six buttons (Menu is two buttons). General information...

  • Page 26: Resolution And Print Quality

    4048-1xx Resolution and print quality • IET, PictureGrade™, print resolution, print darkness, and toner saver can all be set independently of each other through the data stream. • Control panel menus let a user independently set PictureGrade and print resolution. •...

  • Page 27: Memory And User Flash Memory

    4048-1xx Memory and user flash memory Each model has a standard amount of memory (RAM) soldered on the controller card, and a certain number of 100-pin DIMM slots available for installing additional memory or user flash memory options. Models Memory 101 and 111 Standard memory 32MB...

  • Page 28: Print Area

    Fit to page Edge to edge Supplies Approximate Print cartridge Average yield coverage Lexmark Return Program 6,000 print cartridges 12,000 Regular cartridges (without Lexmark 6,000 Return Program terms and 12,000 conditions) Fonts Fonts/options All models PCL bitmapped PCL scalable PostScript scalable...

  • Page 29: Media And Paper Handling

    4048-1xx Media and paper handling Media The following table shows the supported media, media weights and media textures which together provide optimal print quality across a variety of media. Media supported All models Paper Card stock Transparency Labels Envelope Bond Media weights Heavy Normal...

  • Page 30: Standard And Optional Paper Sources

    4048-1xx Standard and optional paper sources Models Media sources 101, 102 Standard Standard input sources: • Integrated 250–sheet tray The 250-sheet drawer supports the following sizes: A4, A5, JIS B5, folio, letter, legal, executive, and statement. • Multipurpose feeder Standard output destination (150-sheet sensing bin) Duplex (standard in models 101 and 102, only) Options...

  • Page 31: Input Media Sources

    4048-1xx Input media sources Supported input sizes Letter 11 x 17 Legal Folio Statement JIS-B4 JIS-B5 Executive Universal 7 3/4 envelope 9 envelope 10 envelope DL envelope C5 envelope B5 envelope Other envelope Size supported without size sensing. General information...

  • Page 32: Output Media

    4048-1xx Output media 150-sheet 20-sheet Supported output sizes standard bin rear exit Letter Legal 11 x 17 Folio Statement JIS-B4 JIS-B5 Executive Universal 7 3/4 envelope 9 envelope 10 envelope DL envelope C5 envelope B5 envelope Other envelope * Size supported, but results may be unacceptable. 1-10 Service Manual...

  • Page 33: Acronyms

    4048-1xx Acronyms ASIC Application-Specific Integrated Circuit Charge Roll Cyclic Redundancy Check Direct Current Developer Roll DIMM Dual In-line Memory Module DRAM Dynamic Random Access Memory Error Checking and Correction EPROM Erasable Programable Read-Only Memory Field Replaceable Unit Ground HVPS High Voltage Power Supply Image Enhancement Technology Kilobyte Liquid Crystal Display...
  • Page 34 4048-1xx 1-12 Service Manual...

  • Page 35: Diagnostic Information

    4048-1xx 2. Diagnostic information Start CAUTION: Unplug power from the printer before connecting or disconnecting any cable, assembly, or electronic card. This is a precaution for personal safety and to prevent damage to the printer. This chapter contains the codes and diagnostic tools to aid in providing corrective action for a malfunctioning printer.

  • Page 36: Power-On Reset (Por) Sequence

    4048-1xx Power–On Reset (POR) sequence The following is an example of the events that occur during the POR sequence when the printer is turned on. 1. Diamonds are displayed on the operator panel. 2. While code is being loaded into DRAM, dots scroll across the operator panel.

  • Page 37: Symptom Tables

    4048-1xx Symptom tables POST symptom table These symptoms may appear during the POST (Power-on Self Test). See “Power–On Reset (POR) sequence” on page 2-2 the sequence when a printer is turned on. Symptom Action The main motor, cooling fan and “Cover interlock switch fuser do not come on.

  • Page 38: Printer Symptom Table

    4048-1xx Printer symptom table Symptom Action Dead machine (no power) “Dead machine service check” on page 2-39. Fan noisy or not working “Cooling fan service check” on page 2-36. Fuser parts melted “Hot fuser service check” on page 2-41. Fuser heater does not activate “Cold fuser service check”...
  • Page 39 4048-1xx Symptom Action Printer not communicating with “Parallel port service check” host on page 2-49. Paper wrinkled or bent “Paper “trees,” wrinkles, stacks poorly or curls” on page 2-49. Top cover will not close “Cover interlock switch service check” on page 2-37.

  • Page 40: Messages And Error Codes

    4048-1xx Messages and error codes Service error codes Service error codes are generally non-recoverable except in an intermittent condition when you can POR the printer to temporarily recover from the error condition. Service error codes (9xx) Error Description Action RIP software Server firmware problem.
  • Page 41 4048-1xx Service error codes (9xx) (continued) Error Description Action Fuser error Fuser is too hot during printing or when printer is idle. Go to “Fuser service check” on page 2-40. Fuser error An open circuit has been detected in the fuser thermistor circuit.
  • Page 42 4048-1xx Service error codes (9xx) (continued) Error Description Action LV Power Supply The low voltage power supply zero crossover test failed. Check the LVPS for correct installation. Make sure the connector on the LVPS assembly is firmly seated with the connector on the interconnect card connector.
  • Page 43 4048-1xx Service error codes (9xx) (continued) Error Description Action Code CRC <loc> Replace the controller card. Where <loc> = CRC Failure or ECC Failure on the controller card. Controller card Error codes 956, 957, and 959 are controller card failures. Perform a power on reset (POR).
  • Page 44 4048-1xx Service error codes (9xx) (continued) Error Description Action Download emulation Perform the following: CRC failure. Checksum 1. Disable the downloaded emulations. failure detected in the “Download Emuls” on emulation header or page 3-24. emulation file. 2. Reprogram the downloaded emulations.

  • Page 45: User Attendance Messages

    4048-1xx User attendance messages User attendance messages Message Explanation Remove the print cartridge and install a new cartridge. input source This message displays when the user should custom type name change the media installed in one of the input options. •...
  • Page 46 4048-1xx User attendance messages (continued) Message Explanation input source This message displays when the user should type size change the media installed in one of the input options. • <input source>=Tray 1, Tray 2, Tray 3, or MP feeder. • <type>=Bond, Card stock, Colored, Envelope, Labels, Ltrhead, Plain, Preprint, or Transparency.
  • Page 47 4048-1xx User attendance messages (continued) Message Explanation When the user has selected the selection, this message is displayed. The following actions may be taken: • Press Go to confirm the selection. All jobs are deleted. • Press Return or Stop to cancel the delete operation.
  • Page 48 4048-1xx User attendance messages (continued) Message Explanation Tray x=Tray 2 or Tray 3. This message is displayed when a paper handling option has been hot unplugged. The printer requires the reinstallation of the option to print a page which has been formatted by the interpreter before the option was removed.
  • Page 49 4048-1xx User attendance messages (continued) Message Explanation Input source=Tray 1, Tray 2, Tray 3, or MP Feeder. Type=Bond, Cardstock, Colored, Envelope, Labels, Ltrhead, Plain, Preprint, Trnsprncy. Size=letter, legal, B5, A4, A5, Exec, Univ., Folio, or Stmt. The following actions may be taken: •...
  • Page 50 4048-1xx User attendance messages (continued) Message Explanation Error 32 displays when the top cover is closed and an unsupported print cartridge is detected. It may take the printer 10-20 seconds to determine if the print cartridge is supported. Depending on the setting of the Machine Class ID, the printer may be allowed to print pages during this 10-20 second interval.
  • Page 51 4048-1xx User attendance messages (continued) Message Explanation This message displays when the printer memory is insufficient to perform the Flash Memory Defragment operation. Note: This message is posted prior to the actual start of the defragment operation. The printer code determines if enough printer memory is available to complete the defragment operation.
  • Page 52 4048-1xx User attendance messages (continued) Message Explanation This message displays when there is not enough memory available to continue processing a job and Print and Hold feature is in use. The printer frees memory by deleting the oldest Reserve Print and Verify Print jobs. It deletes only the amount needed to continue the incoming job.
  • Page 53 4048-1xx User attendance messages (continued) Message Explanation A firmware card containing network code is installed on a non-network printer or a non- network card is installed on a network printer. Press and hold Go while powering the printer. The unsupported card will be ignored. Remove the card.
  • Page 54 4048-1xx User attendance messages (continued) Message Explanation This message displays when the printer detects an unformatted flash at power on. Press Go to clear the message. The flash is marked as bad and normal operation continues. Flash operations are not allowed until the flash is formatted.
  • Page 55 4048-1xx User attendance messages (continued) Message Explanation This error displays when too many flash options are installed in the printer. The following options may be taken: • Turn off the printer and remove the extra flash options. • Press Go to clear the message. The extra flash options are ignored.

  • Page 56: Paper Jam Messages

    4048-1xx Paper jam messages Repeating jams or jam messages can be caused by any of the following: • Faulty pick solenoids or worn cams of the solenoids. • Faulty flags or springs. • Worn backup rollers at the reference guide. •...
  • Page 57 4048-1xx Paper jam messages (continued) Message Explanation A piece of media is most likely jammed in the duplex area. Remove tray 1 and pull down the lever to access the jam area. If the paper is not in the duplex area, then check the rear of the printer by opening the rear door.

  • Page 58: Sub Error Codes

    4048-1xx Sub error codes The sub error codes are helpful troubleshooting a paper path problem. Each status byte has a different level of troubleshooting value for each area of the printer. The following table displays up to 8 status bytes of data. Some or all of these bytes may be used to help diagnose a printer problem.
  • Page 59 4048-1xx Values In the table below, the values for common variables are listed below: • media source 10=Multipurpose tray (MPT) 11=Tray 1 12=Tray 2 13=Tray 3 80=Duplex unit • media size 1=Letter 2=Legal 3=B5 4=A4 5=Executive 6=A5 7=Custom size 9=7¾ in. envelope A=#9 Envelope B=#10 Envelope C=8.661 in.
  • Page 60 4048-1xx Sub error codes First 6 bytes sub Possible error code data Explanation error (xx can be any message value) This code indicates that the input sensor x2 x3 is still actuated from the first sheet and the second sheet is ready to arrive at the sensor.
  • Page 61 4048-1xx Sub error codes (continued) First 6 bytes sub Possible error code data Explanation error (xx can be any message value) The input sensor was covered (activated) during POST. • Clear the media or debris from the printer. • Run the base sensor test (input sensor) from the diagnostic tests menu to test the input sensor and flag for correct operation.
  • Page 62 4048-1xx Sub error codes (continued) First 6 bytes sub Possible error code data Explanation error (xx can be any message value) The imaged page is not the expected page. (x1=media size, x2=media source) Check the pass thru sensor to make sure it is operating properly.
  • Page 63 4048-1xx Sub error codes (continued) First 6 bytes sub Possible error code data Explanation error (xx can be any message value) Input sensor never became uncovered from page ahead while trying to feed media out of path during warm-up. Paper originally detected at option tray pass thru sensor.
  • Page 64 4048-1xx Sub error codes (continued) First 6 bytes sub Possible error code data Explanation error (xx can be any message value) The exit sensor at the fuser is activated by a piece of media indicating there is a piece of media in the machine during POST.
  • Page 65 4048-1xx Sub error codes (continued) First 6 bytes sub Possible error code data Explanation error (xx can be any message value) The fuser exit sensor was never activated by the leading edge of the media fed through the printer. • This error can be displayed after a 201 paper jam.
  • Page 66 4048-1xx Sub error codes (continued) First 6 bytes sub Possible error code data Explanation error (xx can be any message value) This error can be caused by the input sensor not being activated by a page that was known to have been picked. (x1=size, x2=media source) •...
  • Page 67 4048-1xx Sub error codes (continued) First 6 bytes sub Possible error code data Explanation error (xx can be any message value) Duplex sensor covered, paper not expected (paper in duplex during warm- Duplex sensor never changed state when sheet left duplex (possible sticky sensor). (x1+x2=timeout value).

  • Page 68: Disconnects On The Controller Card

    4048-1xx Disconnects on the controller card Always print a page from each paper source following a repair action. The following table is an aid to find a problem with a cable connection. Error or message Condition Check Connector name if cable is required to connection and description...
  • Page 69 4048-1xx Error or message Condition Check Connector name if cable is required to connection and description unplugged obtain error Pick paper from FD (tray1 feed tray1 solenoid) Print a page from PAPER DUPLEX any source (input sensor, narrow media sensor, and duplex sensor) POST EXIT (exit sensor...

  • Page 70: Service Checks

    4048-1xx Service checks Service checks involve measuring voltages of the LVPS, HVPS, and controller card assembly. Continuity and resistance verifications are done on cables and components as required. Note: When looking at the printed side of a printed circuit board, connectors are designated with “J”...

  • Page 71: Cover Interlock Switch Service Check

    4048-1xx Cover interlock switch service check Note: Make sure a print cartridge is installed and the cover closes all the way, fully engaging the cover open switch lever. Action Cover interlock switch Disconnect the cover interlock cable from the interlock switch. Push the cover interlock switch to the closed position and verify continuity between the bottom and middle terminals.

  • Page 72: Controller Card Service Check

    4048-1xx Controller card service check Warning: Never replace both the operator panel and controller card at the same time. Otherwise, some critical settings will be permanently lost. Action Controller card Check for +5 V dc and +24 V dc from the LVPS assembly card to the controller card assembly.

  • Page 73: Dead Machine Service Check

    4048-1xx Dead machine service check Note: Check the AC line voltage. The voltage should be within the following limits: • 90 V ac–120 V ac for nominal–100 V model printer • 100 V ac–127 V ac for the nominal–110 V model printer •...

  • Page 74: High Voltage Power Supply (Hvps) Service Check

    4048-1xx High voltage power supply (HVPS) service check Action HVPS Check continuity between the HVPS and the Cartridge charge roll, Dr. B (doctor blade), TAR (toner adder roll), the developer roll, and the photoconductor (DC). Check as follows: 1. Turn printer off. 2.
  • Page 75 4048-1xx Cold fuser service check Action Fuser assembly Unplug the printer and disconnect the fuser LVPS heater cable from the LVPS card connector (CN3). See “Low voltage power supply (LVPS)” on page 5-7 for more information. Check for continuity across the fuser heater (pins #1 and #3 or outer pins).

  • Page 76: Main Motor Service Check

    4048-1xx Main motor service check Action Main motor With the printer on, verify +24 V dc on pin #7 at Main motor cable J10 on the controller card assembly. Controller card • If the voltage is correct, check the main assembly motor cable for continuity.

  • Page 77: Operator Panel Service Check

    4048-1xx Operator panel service check Warning: Never replace both the operator panel and controller card at the same time. Otherwise, some critical settings will be permanently lost. Inspect the operator panel cable for damage. Make sure the cable is plugged in securely. Run POST and check for proper operation.

  • Page 78: Transfer Roll Service Check

    4048-1xx Transfer roll service check Action Transfer assembly roll Check the springs in the left and right transfer roll bearings. The bearing assemblies should support the transfer roll, applying even pressure to the PC drum. The roll should rotate evenly and smoothly. Replace the transfer roll assembly if the springs or bearings indicate damage or lack of proper function.

  • Page 79: Paper Feed Service Checks

    4048-1xx Paper feed service checks Paper picks and advances approximately four inches Action Reference feed Turn printer off and remove the print cartridge assembly and left side cover. Backup roller assembly With a left finger, rotate the main motor Paper feed gear counterclockwise while using a right finger to Drive assembly resist gear movement in the reference feed...
  • Page 80 4048-1xx Paper jam error indication during POST Action Stack control flags If the exit sensor flag is not resting within the Photo sensor paper exit sensor during POST, the printer indicates Make sure the flag is operating freely and correctly. Replace the photo sensor and/or the stack control flag as necessary.
  • Page 81 4048-1xx Paper picks but stops half way through the printer Action Input paper feed sensor Make sure the input paper feed sensor is Controller card working properly. assembly Check for a broken or stuck flag on the input paper feed sensor. Make sure the cable is seated on the controller card assembly (J20).
  • Page 82 4048-1xx Paper never picks Action Paper tray Make sure the paper tray and paper are correctly positioned. Check the input tray for missing or broken parts. Replace the tray as necessary. Paper feed solenoid Make sure solenoid is installed correctly and Controller card its cable is plugged into the controller card assembly...

  • Page 83: Parallel Port Service Check

    4048-1xx Paper “trees,” wrinkles, stacks poorly or curls Action Fuser assembly This problem is most likely due to a worn backup roller. A worn backup roller causes the printer to run hotter than required for the media being printed. Excessive heat can cause paper treeing problems, poor stacking, or excessive curl.

  • Page 84: Print Quality Service Checks

    4048-1xx Print quality service checks Blank page Action Print cartridge Remove the print cartridge and gently shake (not a FRU) the assembly to evenly distribute the toner. Ensure clean electrical contacts on the right side of the cartridge. Printhead Blank pages can be caused by a defective Printhead cable printhead assembly, HVPS, or controller card HVPS...
  • Page 85 4048-1xx Black page Note: Incorrect laser exposure or incorrect charging of the photoconductor by the charge roll causes an all black page. Action HVPS contacts Check the contacts for contamination and correct installation. Replace as necessary. Controller card Ensure the HVPS to controller card and charge assembly roll cables are correctly installed.
  • Page 86 4048-1xx Heavy background Poor development or poorly charged toner particles cause excessive background. This is more noticeable as the print cartridge nears end of life. Action Print cartridge Make sure the print cartridge is correctly (not a FRU) installed and the high voltage contacts are clean.
  • Page 87 4048-1xx Variation in image density horizontally across page Action Print cartridge The charge roll may have unbalanced pressure Right guide assembly against the PC drum. Check for equal forces at Left guide assembly both ends of the charge roll. If one side has a much lower force than the other, check the spring of the guide assembly.
  • Page 88 4048-1xx Light print Action Print cartridge Make sure the print cartridge is installed (not a FRU) correctly and is not low on toner. If the problem continues, install a new cartridge. Transfer roller Check the transfer roller for signs of toner HVPS contact (transfer buildup and contamination.
  • Page 89 4048-1xx Toner on back of page Action Print cartridge Inspect the overall paper path for signs of (not a FRU) spilled toner. Gently clean the contaminated areas with a soft cloth. Fuser assembly The fuser belt can deposit toner on the back of the paper if toner is building up on the belt edges.

  • Page 90: Solving Print Quality Problems

    8. • Make sure you are using recommended print media. Refer to the Card Stock & Label Guide available on the Lexmark Web site at www.lexmark.com. • If the customer is printing on transparencies, card stock, or labels, be sure to check the Paper Type in the printer driver or operator panel.
  • Page 91 4048-1xx Problem Action Toner smudges appear • Make sure the paper is straight and on the front or back of unwrinkled. the page. • Check for loose toner in the printer. • Clean the printer. • If the problem persists, replace the cartridge.
  • Page 92 • Change the media texture setting. You can download the latest driver from the Lexmark Web site, www.lexmark.com. The print is getting light • The message does not display if a print...
  • Page 93 4048-1xx Problem Action The media skews or • Don’t overfill tray 1 or the optional tray 2 (see buckles. media capacities in the media types and sizes table in the User’s Reference). • Make sure the paper guides are flush against the edges of the media.
  • Page 94 4048-1xx Problem Action • Make sure the tray is pushed all the way in. displays even though • Press Go. there is paper loaded in the optional tray 2 or tray 3. The printer does not • Press Go or open and close the printer front print after a paper jam cover to restart the printer.

  • Page 95: Diagnostic Aids

    4048-1xx 3. Diagnostic aids This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the problem. Additional service menus Several service menus are available by selecting particular keys during POR. Diagnostics 1. Press and hold Go The Diagnostics Mode group Mode and Return.

  • Page 96: Diagnostics Mode

    4048-1xx Diagnostics Mode To run the printer diagnostic tests described in this chapter, you must put the printer in Diagnostics Mode. Entering Diagnostic Mode 1. Turn the printer off. 2. Press and hold the Go and Return buttons. 3. Turn the printer on. 4.
  • Page 97 4048-1xx DEVICE TESTS (only displays if flash is installed) Flash Test PRINTER SETUP Defaults Page Count Perm Page Count Serial Number Engine Setting 1 Engine Setting 2 Engine Setting 3 Engine Setting 4 Model Name Configuration ID Edge to Edge Par S Strobe Adj EP SETUP EP Defaults...

  • Page 98: Registration

    4048-1xx REGISTRATION To set print registration: 1. Select REGISTRATION from the Diagnostics menu. The Top margin sign/value pair blinks. This indicates it is the margin value being changed. 2. To select the margin value to be changed press Select until the margin value pair you want to change is blinking.

  • Page 99: Print Tests

    4048-1xx PRINT TESTS Tray 1, Tray 2, Tray 3, or MP Feeder Input source print tests can verify that the printer can print on media from the installed input sources. Only installed sources appear in the menu. To run the input source test: 1.

  • Page 100: Hardware Tests

    4048-1xx Prt Quality Pgs To print the Print Quality pages: 1. Select PRINT TESTS from Diagnostics Mode. 2. Select Prt Quality Pgs. 3. Press Select. Four pages print. Additional button presses are ignored until the pages have printed. If duplex is selected, the pages print front and back.
  • Page 101 4048-1xx DRAM Test The purpose of this test is to check the validity of DRAM, both standard and optional. The test writes patterns of data to SDRAM to verify that each bit in memory can be set and read correctly. To run the SDRAM Memory Test: 1.
  • Page 102 4048-1xx Parallel Wrap This test is used with a wrap plug to check operation of the parallel port hardware. Each parallel signal is tested. To run the Parallel Wrap Test: 1. Disconnect the parallel interface cable and install the wrap plug (P/N 1319128).

  • Page 103: Duplex Tests

    4048-1xx 6. Once the maximum count is reached the test stops. The power indicator goes on solid and the final results display. 7. Press Return or Stop to exit the test. DUPLEX TESTS Quick Test This test is used to verify that the duplex Top Margin is set correctly. This test prints a duplexed version of the Quick Test page that can be used to adjust the Top Margin for the backside of the duplexed page.
  • Page 104 4048-1xx 3. Select Single to print a single duplex page or Continuous to continue printing until Return or Stop is pressed. The printer attempts to print the Quick Test Page from the default paper source. If the default paper source only supports envelopes, then the page is printed from Tray 1.
  • Page 105 4048-1xx Sensor Test This test is used to determine whether or not the duplex sensors and switches are working correctly. 1. Select Sensor Test from the Duplex Tests menu. 2. Manually actuate each of the duplex sensors. When the sensor/switch is closed, (closed) displays, when the sensor/switch is open, (open) displays.

  • Page 106: Input Tray Tests

    4048-1xx INPUT TRAY TESTS Feed Test This test is used to determine if the input tray sensors are working correctly. Observe the paper path as blank media is being fed through the printer. The upper front door cannot be opened during the feed test.
  • Page 107 4048-1xx 3. A list of sensors appears, depending upon the input source selected. For example, if tray 2 were selected: refers to tray present sensor. refers to pass thru sensor. indicates the sensor is open. indicates the sensor is closed. Not all sources have the same set of sensors.

  • Page 108: Base Sensor Test

    4048-1xx BASE SENSOR TEST Base sensor test is used to determine if the sensors inside the printer are working correctly. To run the Base Sensor Test: 1. Select BASE SENSOR TEST from the Diagnostics Mode. 2. Select the sensor to test. The following sensors may be tested: Toner (toner optical sensor) Input (input sensor) Output (exit sensor)

  • Page 109: Printer Setup

    4048-1xx 2. Select Go to continue. Select Stop or Return to exit. The results are displayed and the power indicators turns on solid: 3. Press Go, Return, or Stop to return to the DEVICE TESTS menu. PRINTER SETUP Defaults Selections are U.S. or Non-U.S. This setting affects the following defaults: Printer setting U.S.
  • Page 110 4048-1xx Page Count Reset the page count when an engine card is replaced. To reset the page count: 1. Select Page Count from the PRINTER SETUP menu. 2. The leftmost number blinks. Use Menu to increase or decrease the number and press Select to move to the next digit to the right.

  • Page 111: Ep Setup

    4048-1xx EP SETUP EP Defaults Restores all EP settings to factory default values. Selections are Restore and Do Not Restore. Fuser Temp Changing this setting can reduce paper curl or melting of some letterhead images. Selections are Normal (default), Lower, and Lowest.

  • Page 112: Error Log

    4048-1xx ERROR LOG Display Log The error log provides a history of printer errors. It contains the 12 most recent errors that have occurred on the printer. The most recent error displays in position 1 and the oldest error displays in position 12 (if 12 errors have occurred).
  • Page 113 Sub error codes Next error code The printed error log can be faxed to Lexmark or your next level of support for verification or diagnosis. This report can also be printed from the Configuration Menu. Because you can clear error logs, the contents of this log may not match the contents when you view the error log.
  • Page 114 4048-1xx Clear Log 1. Select Clear Log from the Error Log menu. 2. Press Yes to confirm. Select No to exit without clearing the log. 3. Press Return to exit the Clear Log menu after clearing the log. Exit Diagnostics Select Exit Diagnostics to exit the Diagnostic Mode and return to normal mode.

  • Page 115: Configuration Menu

    4048-1xx Configuration Menu Entering CONFIG MENU 1. Turn the printer off. 2. Press and hold the Select and Return buttons. 3. Turn the printer on. 4. Release the buttons when displays on the operator panel. The menu items appear on the operator panel in the order shown: Maint Cnt Value Reset Maint Cnt Prt Quality Pgs...

  • Page 116: Maint Cnt Value

    4048-1xx Maint Cnt Value This menu lets you view the maintenance count value. It only displays if Maintenance Warning and Intervention function is enabled in the configuration ID. The maintenance interval is determined by page count. Select Maint Cnt Value from the CONFIG MENU. Press Return to exit.

  • Page 117: Prt Quality Pgs

    4048-1xx Prt Quality Pgs To print the Print Quality Pages: 1. Select Prt Quality Pgs from CONFIG MENU. 2. Press Select. Four pages print. Additional button presses are ignored until the pages have printed. If duplex is selected, the pages print front and back.

  • Page 118: Download Emuls

    4048-1xx Download Emuls This menu item only displays if a downloaded emulator is installed. To disable downloaded emulations: 1. Select Download Emuls from CONFIG MENU. 2. Select Disable. The printer performs POR and starts as if the downloaded emulations were not loaded. To reactivate downloaded emulations, restart the printer.

  • Page 119: Energy Conserve

    4048-1xx Energy Conserve Select On to allow access to the Power Saver menu. If you select Off, an additional item appears in the Power Saver menu. Disable lets you enable or disable Power Saver from the customer menu. ERROR LOG “ERROR LOG”...

  • Page 120: Paper Prompts

    4048-1xx Print Log Additional diagnostic information is available when you print the error log. This report can also be printed from the Diagnostics Mode. “Print Log” on page 3-19. Also, the error log printed from the Diagnostics Mode contains additional debug information for 9xx errors than the error log printed from the Configuration Menu.

  • Page 121: Paper Jams

    4048-1xx Paper jams Most paper jams are caused by improper print media or incorrect loading of the media. Note: To clear the Paper Jam error message, you must remove all jammed print media from the entire paper path. The following illustration shows the path that print media travels through the printer.
  • Page 122 4048-1xx 3-28 Service Manual...

  • Page 123: Repair Information

    4048-1xx 4. Repair information Warning: Read the following before handling electronic parts. Handling ESD-sensitive parts Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent damage to ESD-sensitive parts, follow the instructions below in addition to all the usual precautions, such as turning off power before removing logic cards: •...

  • Page 124: Adjustments

    4048-1xx Adjustments Printhead assembly adjustment The printhead needs to be correctly positioned after it has been removed. Align it to the frame or use the same position as the removed printhead. Skew is caused by a sheet being fed through the printer while misaligned.
  • Page 125 4048-1xx 2. Fold the printed test page on the left side so that a few millimeters of grid lines wrap around the outside of the fold. 3. Fold a second vertical fold near the center so that the left side top edge aligns with the right side top edge.
  • Page 126 4048-1xx 5. After obtaining a properly adjusted image on the paper, tighten all three screws. 6. After adjusting the printhead, if necessary, adjust registration of the left, right, top and bottom margins. See “REGISTRATION” on page 3-4. Note: Printhead misalignment results in skewed horizontal lines but a consistent margin top to bottom of page.

  • Page 127: Adjusting Paper Feed Alignment (Skew)

    4048-1xx Adjusting paper feed alignment (skew) When a reference feed assembly is removed, it requires realignment. Use a long shank (6–inches) Phillips screwdriver to adjust the rear screw holding the assembly in place. It is accessed through the hole in the main drive assembly. It is between the controller card cage and the main motor board.

  • Page 128: Lubrication

    4048-1xx Lubrication Several FRUs must be lubricated when installed. The following diagrams indicate the units requiring lubricant and show where to place it. Place a drop size or less at each location and then rotate the gears or mechanism to evenly distribute the lubricant. Use Nyogel 744 (P/N 99A0394) or IBM 23 (P/N 99A0462).

  • Page 129: Reassembly

    4048-1xx P/N 56P2359 MPF pick roll assembly P/N 56P2327 Exit gear drive assembly P/N 56P2302 Rear cover assembly Reassembly Ensure all cables are reconnected when reassembling the printer. The printer may not detect a disconnected sensor in some areas without extensive running. Note: Always print a page from each paper source to verify reassembly.

  • Page 130: Removal Procedures

    4048-1xx Removal procedures Be sure to unplug the power cord whenever you are working on the printer with one of the covers removed. Remove the print cartridge and paper tray before you perform removal procedures. Unless otherwise stated, reinstallations are in reverse order of removal.

  • Page 131: Front Cover Removal

    4048-1xx Front cover removal 1. Open the front cover. 2. Remove the two screws holding the front cover to the hinge arm (A). 3. Unlatch the ends of the hinge arms. Repair information...
  • Page 132 4048-1xx 4. Remove the screw (B) from the operator panel cable cover and remove the cable cover. 5. Disconnect the operator panel cable (C) from the operator panel. 6. Remove the front cover with the operator panel attached. If replacing the front cover, remove the operator panel. See “Operator panel assembly removal”...

  • Page 133: Top Cover Assembly Removal

    4048-1xx Top cover assembly removal 1. Remove the front cover. See “Front cover removal” on page 4-9. 2. Remove the two screws as shown (A). 3. Remove the E-clips from both hinges that connect the left and right guides to the top cover (B). 4.

  • Page 134: Right Side Cover Removal

    4048-1xx Right side cover removal 1. Remove the paper tray. 2. Open the front cover. 3. Open the MPF door. 4. Remove the screw below the front cover which fastens the side cover to the frame (A). 5. Open the rear cover and remove the second screw down from the top left corner (B).
  • Page 135 4048-1xx 7. Unlatch the cover from the frame behind the front of tray (C). 8. Remove the cover. The MPF door may need to be lifted slightly for the side cover to clear. 4-13 Repair information...

  • Page 136: Left Side Cover Removal

    4048-1xx Left side cover removal 1. Open the front cover and the MPF door. 2. Disengage the two latches (A) located in the front and top. 3. Swing the left side cover away from the printer. 4-14 Service Manual...

  • Page 137: Rear Cover Removal

    4048-1xx Rear cover removal 1. Remove the paper tray. 2. Remove the right side cover. See “Right side cover removal” on page 4-12. 3. Remove the left side cover. See “Left side cover removal” on page 4-14. 4. Disconnect the sensor cable (in-line connector) (A) below the lower left corner of the controller cage.
  • Page 138 4048-1xx 5. Open the exit tray (rear door). 6. Remove the five remaining screws (B). There are a total of six. 7. Lift the top cover slightly with one hand while pulling out on the rear cover. Installation notes: • Handle carefully.

  • Page 139: Rear Exit Door Removal

    4048-1xx Rear exit door removal 1. Open the rear exit door. 2. Use your index finger or flatblade screwdriver to disengage the left (facing the back of printer) hinge (A) from the rear cover. 3. Swing the left side out to clear the printer and then move the door to the left to disengage the right hinge.

  • Page 140: Output Tray Full Flag Removal

    4048-1xx Output tray full flag removal 1. Open the front cover. 2. Remove the two screws (A) holding the front top cover. 3. Remove the two screws (B) from the rear. 4. Lift the rear part of the top cover to clear the output tray full flags.
  • Page 141 4048-1xx 5. Press the side of the flag to unclip the flag from the frame. 6. Repeat to remove the other flag. 4-19 Repair information...

  • Page 142: Operator Panel Cable Removal

    4048-1xx Operator panel cable removal 1. Remove the left side cover. See “Left side cover removal” on page 4-14. 2. Remove the inner shield (A). 3. Loosen the five screws (B), slide the controller card cage cover toward the rear, and remove. 4.
  • Page 143 4048-1xx 8. Disconnect the cable from the operator panel card. 4-21 Repair information...

  • Page 144: Operator Panel Assembly Removal

    4048-1xx Operator panel assembly removal Warning: Never replace both the operator panel and controller card at the same time. Otherwise, some critical settings will be permanently lost. 1. Remove the operator panel cable. See “Operator panel cable removal” on page 4-20.
  • Page 145 4048-1xx 4. Press each of the four tabs (A) while gently prying up the same corner of the operator panel assembly (B) until the panel is free. 5. Remove the operator panel assembly. 4-23 Repair information...

  • Page 146: Duplex Tray Assembly Removal

    4048-1xx Duplex tray assembly removal 1. Disconnect the computer and power cables at the back of the printer, if not already removed. 2. Remove the print cartridge. 3. Tilt the printer on its back. 4. Remove the five screws (A) holding the bottom panel. 5.

  • Page 147: Bottom Pan Removal

    4048-1xx Bottom pan removal This removal is for a model (4048-111) without a duplex unit. 1. Disconnect the computer and power cables at the back of the printer, if not already removed. 2. Remove the print cartridge. 3. Tilt the printer onto its back. 4.

  • Page 148: Fuser Assembly Removal

    4048-1xx Fuser assembly removal 1. Unplug the printer. 2. Remove the left side cover. See “Left side cover removal” on page 4-14. 3. Remove the right side. See “Right side cover removal” on page 4-12. 4. Remove the rear cover. See “Rear cover removal”...
  • Page 149 4048-1xx 7. Using a long shank Phillips screwdriver, remove the four screws (C) which fasten the fuser metal frame to the printer frame. 8. Carefully slide the fuser out while pressing the duplex diverter. Non-duplex models do not have the diverter. The front cover door must be closed to remove the fuser.
  • Page 150 4048-1xx Installation notes: • During reassembly of the fuser, keep the front door closed to prevent separation of the roller in the fuser. • Be sure to route the cables through the frame and through the cable retainer (D). 4-28 Service Manual...

  • Page 151: Fuser Paper Exit Guide Assembly Removal

    4048-1xx Fuser paper exit guide assembly removal 1. Unplug the printer. 2. Remove the left side cover. See “Left side cover removal” on page 4-14. 3. Remove the right side. See “Right side cover removal” on page 4-12. 4. Remove the rear cover. See “Rear cover removal”...
  • Page 152 4048-1xx 6. Carefully slide the fuser out far enough to reach the screw that holds the exit guide (B). Remove the screw. Note: Insert the screwdriver through the top cover to access the screw with the minimum fuser movement. If there is a washer between the guide and the fuser, be sure to reinstall the washer.
  • Page 153 4048-1xx 7. Ease the guide back and forth while sliding it to the left and into the opening in the metal frame to allow the right side to disengage from the frame. 8. Swing the right side out enough to clear the metal frame. 9.
  • Page 154 4048-1xx Installation notes: • During reassembly of the fuser exit guide assembly, keep the front door closed to prevent separation of the roller in the fuser. • Be sure to route the cables through the frame and through the cable retainer (C). 4-32 Service Manual...

  • Page 155: Fuser Exit Sensor Removal

    4048-1xx Fuser exit sensor removal 1. Remove the fuser paper exit guide. See “Fuser paper exit guide assembly removal” on page 4-29. 2. Use your right index finger to push the tangs (A) of the sensor out of the metal frame. 3.

  • Page 156: Cartridge Contact Assembly Removal

    4048-1xx Cartridge contact assembly removal 1. Remove the HVPS. See “HVPS card removal” on page 4-75. 2. Remove the cartridge contact assemblies (A). Note: The lower right cartridge contact (to the transfer roll) is a different color from the others. Be sure to reinstall this one in the same location.

  • Page 157: Tray Damper And Spring Removal

    4048-1xx Tray damper and spring removal 1. Remove the right side cover. See “Right side cover removal” on page 4-12. 2. Remove the tray damper spring from the printer frame post (A). 3. Rotate the lever counterclockwise as far as possible and lift out. 4-35 Repair information...

  • Page 158: Door Latch Removal

    4048-1xx Door latch removal 1. Remove the right side cover. See “Right side cover removal” on page 4-12. 2. Remove the two screws (A). 3. Remove the left side cover. See “Left side cover removal” on page 4-14. 4. Remove the latch on the left side. 4-36 Service Manual...

  • Page 159: Paper Guide Roller Removal

    4048-1xx Paper guide roller removal 1. Remove the HVPS. See “HVPS card removal” on page 4-75. 2. Remove the print cartridge. 3. Remove the upper body MPF assembly. See “Upper MPF housing assembly (with paper flag) removal” on page 4-66. 4.

  • Page 160: Charge Roll Removal

    4048-1xx Charge roll removal Warning: Handle the charge roll only at the ends and with clean dry hands. Otherwise, use a piece of paper between the charge roll and your fingers. 1. Grasp the charge roll on the right end. Hold the front cover as closed as possible while unsnapping the charge roll in the direction of the arrow.

  • Page 161: Right Guide Removal

    4048-1xx Right guide removal 1. Remove the top cover. See “Top cover assembly removal” on page 4-11. 2. Remove the HVPS. See “HVPS card removal” on page 4-75. 3. Remove the charge roll. See “Charge roll removal” on page 4-38. 4.

  • Page 162: Left Guide Removal

    4048-1xx Left guide removal 1. Remove the controller card cage. See “Controller card cage (with card in place) removal” on page 4-48. 2. Remove the charge roll. See “Charge roll removal” on page 4-38. 3. Remove the top cover assembly. See “Top cover assembly removal”...
  • Page 163 4048-1xx 7. Disconnect the single conductor cable (spade connector) (D). Note: Removal of the printhead is not necessary but gives better visibility and access. Illustrations are with the printhead removed. See “Printhead removal” on page 4-46. 8. Remove the cable from the retainers between the printer right side and the left guide.

  • Page 164: Cartridge Signature Button Sensor Removal

    4048-1xx Cartridge signature button sensor removal 1. Remove the gear train assembly. See “Main drive assembly removal” on page 4-55. 2. Remove the two screws and the bracket coupling assembly. 3. To protect the charge roll from touching, either remove it (see “Charge roll removal”...

  • Page 165: Transfer Roll Assembly

    4048-1xx Transfer roll assembly Note: Do not touch the transfer roll except on the ends. 1. Unlatch and lift the left transfer support bearing. 2. Unlatch and lift the right transfer support bearing. 3. Remove the transfer roll. Note: After reinstalling the transfer roll, use a thin screwdriver to push the copper tab on the right side fully into the slot.

  • Page 166: Bracket, Paper Detect (Input Sensor) Removal

    4048-1xx Bracket, paper detect (input sensor) removal 1. Remove the print cartridge to expose latches in the bracket. Leave the door open. 2. Remove the duplex tray assembly (see “Duplex tray assembly removal” on page 4-24) or bottom pan in the simplex model (see “Bottom pan removal”...

  • Page 167: D-Roll Shaft Assembly Removal, Tray 1

    4048-1xx D–roll shaft assembly removal, tray 1 1. Remove the left side cover. See “Left side cover removal” on page 4-14. 2. Remove the gear train assembly. See “Main drive assembly removal” on page 4-55. 3. Remove the screw and solenoid (A). 4.

  • Page 168: 3-Pin And 2-Pin Connectors Removal

    4048-1xx 3–pin and 2–pin connectors removal 1. Remove the controller card cage. See “Controller card cage (with card in place) removal” on page 4-48. 2. Remove the rear cover. See “Rear cover removal” on page 4-15. 3. Unplug the wires on both sides of the connectors. 4.
  • Page 169 4048-1xx 4. Lift the rear part of the top cover to clear the output tray full flags. You do not have to disconnect the top cover from the left and right guides to access the printhead. 5. Use a sharp pencil or other tool to mark the position of the printhead on the frame for re-alignment at installation.

  • Page 170: Controller Card Cage (With Card In Place) Removal

    4048-1xx Controller card cage (with card in place) removal 1. Remove the left side cover. See “Left side cover removal” on page 4-14. 2. Remove the four screws that fasten the top cover to the frame. “Top cover assembly removal” on page 4-11.
  • Page 171 4048-1xx 5. Disconnect all cables from the controller card assembly. 6. Remove the three screws (C) in the controller card and one at the front face of the cage. 7. Gently pull the bottom of the cage out and lift up and off the two posts at the top.

  • Page 172: Controller Card Assembly Removal

    4048-1xx Controller card assembly removal Warning: Never replace both the operator panel and controller card at the same time. Otherwise, some critical settings will be permanently lost. 1. Remove the left side cover. See “Left side cover removal” on page 4-14.
  • Page 173 4048-1xx 4. Disconnect all cables and extract the ones from the right side and bottom of the cage. 5. Remove the four screws on the face of the card (D) and three screws on the back holding the USB and parallel port connectors (E).

  • Page 174: Mpf Gear Removal

    4048-1xx MPF gear removal 1. Remove the left side cover. See “Left side cover removal” on page 4-14. 2. Remove the inner shield. 3. Lift the solenoid arm (A) to release the gear. 4. Rotate the main motor (B) counterclockwise until the gear clears the main motor drive bracket (C) 5.

  • Page 175: Main Drive Motor Assembly Removal

    4048-1xx Main drive motor assembly removal 1. Remove the left side cover. See “Left side cover removal” on page 4-14. 2. Remove the screw (A) and remove the inner shield. 4-53 Repair information...
  • Page 176 4048-1xx 3. Disconnect the cable (B) to the card for the drive motor. 4. Remove the four screws (C) holding the metal base plate to the gear train assembly. 5. Remove the motor assembly. Note: Be very careful when reinstalling the motor. Do not allow the motor drive shaft to touch the mating gears until the shaft is fully inserted.

  • Page 177: Main Drive Assembly Removal

    4048-1xx Main drive assembly removal 1. Remove the controller card cage. See “Controller card cage (with card in place) removal” on page 4-48. 2. Remove the inner shield by removing the screw (A). 3. Release the solenoid latch (B). 4. Rotate the drive motor until the MPF gear clears the drive gear bracket.
  • Page 178 4048-1xx 5. Pull the latch (C) away from the shaft and slide the gear off the shaft. 6. Remove the cables from the two cable clamps on the right side of the gear drive. 4-56 Service Manual...
  • Page 179 4048-1xx 7. Remove the six screws (D) in the gear train assembly. 8. Disconnect the drive motor cable. 9. Remove the two screws (E) and the plastic bearing at the upper right corner of the main drive motor. This allows more movement for the gear assembly.

  • Page 180: Exit Drive Motor Removal

    4048-1xx Exit drive motor removal 1. Remove the left side cover. See “Left side cover removal” on page 4-14. 2. Loosen the five screws (A) in the controller card cage cover and slide the cover to the rear and remove it. 3.

  • Page 181: Exit Drive Assembly Removal

    4048-1xx Exit drive assembly removal 1. Remove the controller card cage. See “Controller card cage (with card in place) removal” on page 4-48. 2. If replacing the drive assembly, remove the exit drive motor. See “Exit drive motor removal” on page 4-58.

  • Page 182: Ratchet Drive Removal

    4048-1xx Ratchet drive removal 1. Remove the exit drive assembly. See “Ratchet drive removal” on page 4-60. 2. Gently remove the ratchet drive (A) from the back of the exit drive assembly. 3. Remove the bushing (B) from the exit drive assembly. 4-60 Service Manual...
  • Page 183 4048-1xx Installation: 1. Place the printer on the right side. 2. Install the bushing (C), aligning it with the slots. 3. Insert the ratchet. 4-61 Repair information...

  • Page 184: Reference Feed Assembly Removal

    4048-1xx 4. Complete the installation of the exit drive. Reference feed assembly removal 1. Remove the gear train assembly. See “Main drive assembly removal” on page 4-55. 2. Remove the three screws (A) fastening the assembly plate to the frame. 3.
  • Page 185 4048-1xx 5. Remove the two screws (B) holding the upper body MPF assembly. and carefully lift the assembly out. Note: A sensor flag is attached below the upper body. 6. Remove the screw (C) and inside cover which is adjacent to the assembly plate.
  • Page 186 4048-1xx 8. Remove the reference feed assembly through the front of the printer. Installation note: When a reference feed (reference edge) assembly is removed, reinstallation requires alignment. Use a long shank (approximately 6 inches) Phillips screwdriver to adjust the rear screw holding the assembly in place. Access the adjusting screw through the hole in the main drive assembly between the controller card cage and the main motor board.

  • Page 187: Cartridge Coupling Assembly Removal

    4048-1xx Cartridge coupling assembly removal 1. Remove the left cover. See “Left side cover removal” on page 4-14. 2. Remove the controller card cage. See “Controller card cage (with card in place) removal” on page 4-48. 3. Remove the two screws (A). 4.

  • Page 188: Upper Mpf Housing Assembly (With Paper Flag) Removal

    4048-1xx Upper MPF housing assembly (with paper flag) removal 1. Open the front cover. 2. Remove two screws (A) holding the assembly. 3. Carefully lift the assembly out. Note: A sensor flag is attached below the housing. 4-66 Service Manual...

  • Page 189: Mpf Paper Sensor Removal

    4048-1xx MPF paper sensor removal See the “MPF paper sensor installation:” on page 4-69 information about installing the FRU. 1. Remove the MPF door cover. See “MPF door cover removal” on page 4-8. 2. At the lower right assembly hinge, use a flat blade screwdriver to separate the metal plate from the plastic housing.
  • Page 190 4048-1xx 3. Support the left side with the left hand while separating the left hinge. Note: There is a loaded compression spring (A) on the left side and under the metal plate. Note the location before removing the spring. 4. Rotate the metal plate until you can access the sensor (B). 5.
  • Page 191 4048-1xx MPF paper sensor installation: To verify the spring is correctly reinstalled: 1. Reinstall the metal plate. Make sure the compression spring (A) is in the proper location and captured at its ends. 2. Release the solenoid latch (A). 3. Rotate the main motor counterclockwise until the gear arm engages the solenoid latch.

  • Page 192: Lower Mpf Housing Assembly Removal

    4048-1xx Lower MPF housing assembly removal 1. Remove the MPF door cover. See “MPF door cover removal” on page 4-8. 2. Remove the left side cover. See “Left side cover removal” on page 4-14. 3. Remove the inner shield (A). 4.
  • Page 193 4048-1xx 5. Disconnect the MPF cable on the right side of the controller card (C) and the toner level sensor (D). 6. Remove the three screws (E) on the front of the lower body MPF assembly and gently remove the assembly. 4-71 Repair information...

  • Page 194: Backup Feed Roller Assembly Removal

    4048-1xx Backup feed roller assembly removal 1. Using a flat-bladed screw driver and springhook, release the spring (A) from the metal anchor. 2. With the screwdriver, remove the backup feed roller assembly. Note: A third assembly is below the upper MPF housing. When one assembly needs replacing, replace all three assemblies one at a time.

  • Page 195: Mpf Pick Roller Assembly Removal

    4048-1xx MPF pick roller assembly removal 1. Remove the left side cover and inner shield. See “Left side cover removal” on page 4-14. 2. Remove the roller cover, one screw. See “Lower MPF housing assembly removal” on page 4-70. 3. Pull the latch (A) away from the shaft and slide the gear off. 4-73 Repair information...
  • Page 196 4048-1xx 4. Remove two screws (B) holding the roller assembly and one screw (C) facing the front of the printer. 5. Remove the roller assembly. Note: Push the MPF plate down to give clearance. Warning: When reinstalling, replace the two screws (B) first and then the front screw (C).

  • Page 197: Hvps Card Removal

    4048-1xx HVPS card removal 1. Remove the right side cover. See “Right side cover removal” on page 4-12. 2. Disconnect the HVPS cable at the top left corner of the board. 3. Remove the four screws (A). 4. Disconnect the charge roll cable (spade connector). 5.

  • Page 198: Lvps Fan Removal

    4048-1xx LVPS fan removal 1. Remove the right side cover. See “Right side cover removal” on page 4-12. 2. Disconnect the fan (A). 3. Remove the two screws (B). 4. Remove the LVPS fan. 4-76 Service Manual...

  • Page 199: Lvps Card Removal

    4048-1xx LVPS card removal 1. Unplug the printer. 2. Remove the right side cover. See “Right side cover removal” on page 4-12. 3. Remove the LVPS fan. See “LVPS fan removal” on page 4-76. 4. Disconnect all cables attached to the LVPS card. The fuser connector has a latch on the back side.

  • Page 200: Inner Link And Outer Link Assembly Removal

    4048-1xx Inner link and outer link assembly removal Note: Links are shown in light color for visibility. They are actually dark in color. 1. Remove the controller card cage. See “Controller card cage (with card in place) removal” on page 4-48.
  • Page 201 4048-1xx 7. Use a flat blade screwdriver to wedge the charge roll arm from the left guide assembly and remove the inner link. 4-79 Repair information...
  • Page 202 4048-1xx 8. Remove the bellcrank while holding the link guide. 4-80 Service Manual...
  • Page 203 4048-1xx 9. Remove the inner link. The outer link can also be removed. Note: The outer link assembly is disconnected and must be reconnected at reassembly. A diagram of the linkages is shown. 4-81 Repair information...

  • Page 204: Cooling Fan Removal

    4048-1xx Cooling fan removal 1. Remove the top cover. See “Top cover assembly removal” on page 4-11. 2. Remove the right side cover. See “Right side cover removal” on page 4-12. 3. Disconnect the fan cable. 4. Remove the two screws (A). 5.

  • Page 205: Locations And Connections

    4048-1xx 5. Locations and connections Exterior locations Locations and connections...

  • Page 206: Connectors

    4048-1xx Connectors Note: Pin number 1 is designated on the printed circuit card by either a white triangle, a number 1, or both. The pin numbers follow chronologically to the opposite end of the connector. Voltages shown on the following pages are made with the printer turned on. CAUTION: Voltages are exposed.
  • Page 207 4048-1xx Controller card assembly connectors (see “Controller card assembly” on page 5-2) # of Connector Name Pin # Signal pins J1–MMTR Mirror motor Ground +24 V dc J2–CO Cover +5 V dc Ground J3–LSU LSU (printhead) Ground Ground +5 V dc (cover closed) Ground J4–DIMM...
  • Page 208 4048-1xx Controller card assembly connectors (see “Controller card assembly” on page 5-2) # of Connector Name Pin # Signal pins J4–DIMM SDRAM Ground (continued) +3.3 V dc Ground J5–OP Operator panel +5 V dc PANEL Ground +3.3 V dc J6–Exit motor Exit motor Ground +5 V dc...
  • Page 209 4048-1xx Controller card assembly connectors (see “Controller card assembly” on page 5-2) # of Connector Name Pin # Signal pins J13–LVPS LVPS control Ground J14–FD Paper feed solenoid +24 V dc only during tray 1 pick J16–EXIT Fuser exit tray full +5 V dc sensor Ground...
  • Page 210 4048-1xx Controller card assembly connectors (see “Controller card assembly” on page 5-2) # of Connector Name Pin # Signal pins J20–Paper Paper input, narrow +5 V dc Duplex media, duplex Ground +5 V dc Ground +5 V dc Ground J21–TRAY 2nd drawer interface +5 V dc +5 V dc...

  • Page 211: Low Voltage Power Supply (Lvps)

    4048-1xx Low voltage power supply (LVPS) Connector Name Pins Pin # Signal Controller Ground card/LVPS control 110 / 220 Ground Volts +5 V dc Ground Ground +24 V dc +24 V dc Heater 100/110 / 220 V ac 100/110 / 220 V ac On/off switch CN4–S/W...

  • Page 212: High Voltage Power Supply (Hvps)

    4048-1xx High voltage power supply (HVPS) Connector Name # of Pins Pin # Signal To controller CN1 (connects Ground card to J19 on the +24 V dc controller card) +5 V dc Charge roll (Terminal) Photoconductor (Contact) Transfer roll (Contact) Development (Contact) roll...

  • Page 213: Preventive Maintenance

    Damaged, missing, or altered covers, especially in the area of the top cover and the power supply cover. • Possible safety exposure from any non–Lexmark attachments. Lubrication specifications Lubricate only when parts are replaced or as needed, not on a scheduled basis.

  • Page 214: Scheduled Maintenance

    4048-1xx Scheduled maintenance The operator panel displays the message at a fixed page count interval. It may be necessary to replace the fuser assembly, transfer roller, charge roll, and pick tires at this interval to maintain the print quality and reliability of the printer.

  • Page 215: Maintenance Kit Parts Group

    4048-1xx Maintenance kit parts group The maintenance kit parts group (P/N 56P2364) includes the following items: • MPF rubber pick roll • Metal plate for tray 1 with pad • Metal plates for optional 250-sheet trays with pads • Rubber pick rolls for optional 250-sheet trays •...
  • Page 216 4048-1xx Service Manual...

  • Page 217: Parts Catalog

    4048-1xx 7. Parts catalog How to use this parts catalog Abbreviations used in the parts catalog include the following: • NS: (Not Shown) in the Asm-Index column indicates that the part is procurable but is not pictured in the illustration. •...

  • Page 218: Assembly 1: Covers

    4048-1xx Assembly 1: Covers Service Manual...
  • Page 219 4048-1xx Assembly 1: Covers Asm- Part Units Description index numbers 1–1 56P2302 Rear cover assembly 56P2301 Rear exit door assembly 56P2306 Top cover assembly 56P2307 Right cover assembly 56P2305 Front cover assembly 56P2303 MPF door cover assembly 56P2342 Language overlay group 56P2353 Operator panel assembly 56P2356...

  • Page 220: Assembly 2: Paper Feed

    4048-1xx Assembly 2: Paper feed Service Manual...
  • Page 221 4048-1xx Assembly 2: Paper feed Asm- Part Units Description index numbers 2–1 56P2304 Stack control flags (output tray full flags) 56P0651 Duplex assembly (101, 102) 56P2365 Paper guide bracket 56P2352 Paper feed roll 56P0655 Paper sensor bracket, one per package 56P0645 Photo sensor, one per package 56P2309...

  • Page 222: Assembly 3: Frame

    4048-1xx Assembly 3: Frame Service Manual...
  • Page 223 4048-1xx Assembly 3: Frame Asm- Part Units Description index numbers 3–1 56P2319 Printhead assembly 56P0629 Cartridge contact assembly (includes 5) 56P0662 Base feet 56P0661 Tray damper 56P0668 Parts packet, screws and E–rings 56P2310 Main tray assembly, 250 56P0667 Door latch (includes 3) 56P0660 Paper guide roller 56P0672...

  • Page 224: Assembly 4: Multipurpose Feeder (Mpf)

    4048-1xx Assembly 4: Multipurpose feeder (MPF) Asm- Part Units Description index numbers 4–1 56P2312 Upper MPF housing assembly 56P2311 Lower MPF housing assembly 56P0615 MPF paper feed cover cap 56P2359 MPF pick roll assembly 56P2358 MPF paper pick gear (order lubricant to use with this gear, P/N 99A0394) Service Manual...

  • Page 225: Assembly 5: Fuser

    4048-1xx Assembly 5: Fuser Asm- Part Units Description index numbers 5–1 56P2330 Fuser assembly, 110 V 56P2331 Fuser assembly, 220 V 56P2332 Fuser assembly, 100 V 56P2355 Fuser paper exit guide assembly 56P0676 Fuser exit spring Parts catalog...

  • Page 226: Assembly 6: Charging

    4048-1xx Assembly 6: Charging 7-10 Service Manual...
  • Page 227 4048-1xx Assembly 6: Charging Asm- Part Units Description index numbers 6–1 56P0640 Charge roll Note: Customer replaceable unit is a different part number; order CRU P/N 56P2341 56P0668 Parts packet, screws and E–rings 56P0669 Pivot hinge (quantity 2) 56P2328 Right guide assembly 56P2329 Transfer roll assembly 56P2340...

  • Page 228: Assembly 7: Electronics And Cables 1

    4048-1xx Assembly 7: Electronics and cables 1 7-12 Service Manual...
  • Page 229 4048-1xx Assembly 7: Electronics and cables 1 Asm- Part Units Description index numbers 7–1 56P2357 LVPS fan and housing assembly 56P2335 Main harness cable assembly, including wiring to the following locations: • LVPS fan/fuser fan • HVPS • Main fan •...

  • Page 230: Assembly 8: Electronics And Cables 2

    4048-1xx Assembly 8: Electronics and cables 2 7-14 Service Manual...
  • Page 231 4048-1xx Assembly 8: Electronics and cables 2 Asm- Part Units Description index numbers 8–1 56P0624 Cover switch cable assembly 56P2317 Operator panel cable assembly 56P0625 Interlock cover switch 56P0645 Photo sensor, included with P/N 56P2311 (lower MPF housing) Available only with P/N 56P2311 6 and 8 56P2313 Paper feed solenoid...
  • Page 232 4048-1xx Assembly 8 (cont.): Electronics and cables II 7-16 Service Manual...
  • Page 233 4048-1xx Assembly 8 (cont.): Electronics and cables II Asm- Part Units Description index numbers 8–19 70G0478 Power cord, US, Bolivia, Canada, Caribbean countries, Columbia, Costa Rica, Dominican Republic, Ecuador, El Salvador, Guatemala, Honduras, Japan, Mexico, Nicaragua, Panama, Peru, Puerto Rico, Saudi Arabia, Taiwan, The Virgin Islands, Venezuela, AP–LV 1339528 Power cord, Bahrein, Cyprus, Iraq,...

  • Page 234: Assembly 9: Sensors

    4048-1xx Assembly 9: Sensors 7-18 Service Manual...
  • Page 235 4048-1xx Assembly 9: Sensors Asm- Part Units Description index numbers 9–1 56P0645 Photo sensor, locations found: A—Paper path exit flag B—Fuser exit sensor C—Paper path below cartridge D—Paper path duplex E—Paper path MPF F—Paper path below cartridge 56P0653 Toner level sensor 56P2350 Cartridge signature button switch 7-19...

  • Page 236: Assembly 10: Options

    4048-1xx Assembly 10: Options 7-20 Service Manual...

  • Page 237: Index

    32MB flash card assembly 56P1427 Optra Forms™ 32 MB flash card asm. 56P1428 Optra Forms 16 MB flash card assembly 56P3845 Lexmark Forms card assembly 56P3304 ImageQuick™ card assembly (T430) 56P3305 PRESCRIBE card assembly 56P3144 PrintCryption card 56P3317 Bar code card 56P1429...
  • Page 238 4048-1xx Assembly 11: Miscellaneous Asm- Part Units Description index numbers 7370971 Field relocation kit 56P2333 110 V maintenance kit 56P2337 220 V maintenance kit 56P2338 100 V maintenance kit 56P2364 Maintenance kit parts group, see “Maintenance kit parts group” on page 6-3.
  • Page 239 4048-1xx Index Numerics Config Menu Demo Mode 3-24 2-pin connector description parts 7-15 Download Emuls 3-24 removal 4-46 Energy Conserve 3-25 – 2xx paper jams 2-22 2-23 entering 3-21 3-pin connector Env Prompts 3-26 parts 7-15 Error Log, Print Log 3-26 removal 4-46...
  • Page 240 4048-1xx Base Sensor Test 3-14 parts catalog description tray removal 4-24 Device Tests Duplex Feed 1 3-11 Flash Test 3-14 duplex input sensor, Sensor Test 3-11 Duplex Tests Duplex Feed 1 3-11 Quick Test Edge to Edge 3-16 Sensor Test 3-11 Energy Conserve 3-25...
  • Page 241 4048-1xx removal 4-26 main drive motor assembly service check 2-40 parts catalog Fuser Temp 3-17 removal 4-53 service check 2-42 maintenance handling ESD-sensitive parts Gap Adjust 3-17 lubrication maintenance kit maintenance kit parts group high voltage power supply (HVPS) preventive card removal 4-75 maintenance approach...
  • Page 242 4048-1xx operator panel cable 4-20 7-15 heavy background 2-52 options light or blurred characters 2-56 memory light print 2-54 paper sources Load Paper displays 2-60 parts catalog 7-20 media skews 2-59 output tray full flags multiple feeds 2-59 parts catalog paper fails to feed 2-59 removal...
  • Page 243 4048-1xx parts reference feed assembly 4-62 removal 4-62 right guide 4-39 registration transfer roll assembly 4-43 removals tray 1 D-roll shaft assembly 4-45 2-pin connector 4-46 tray 1 feed D-roll 4-44 3-pin connector 4-46 tray damper and spring 4-35 bottom pan (non-duplex) 4-25 upper MPF housing assembly 4-66...
  • Page 244 4048-1xx operator panel 2-43 Registration paper feed 2-45 tools parallel port 2-49 Top Margin 3-10 print quality 2-50 top margin transfer roll 2-44 Transfer 3-17 service error codes transfer roll assembly specifications parts catalog 7-11 connectivity removal 4-43 data streams service check 2-44 fonts...

  • Page 245: Part Number Index

    4048-1xx Part number index Description Page 1038693 Serial cable, 50 ft ........7-21 11D0330 Power cord .
  • Page 246 4048-1xx 56P0669 Pivot hinge ......... .7-11 56P0672 Tray body bracket (includes 4) .
  • Page 247 4048-1xx 56P2330 Fuser assembly, 110 V ......6-2, 7-9 56P2331 Fuser assembly, 220 V ......6-2, 7-9 56P2332 Fuser assembly, 100 V .
  • Page 248 4048-1xx 99A0394 Lubricant, Nyogel 744 ....4-6, 6-1, 6-2, 7-5, 7-8 99A0462 Lubricant, IBM 23 ........4-6 99A0545 External serial adapter .

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